Process of making compound metal bodies.



PATENTEb APR. 30, 1907.

J. F. MONNOT. PROCESS OF MAKING COMPOUND METAL BODIES.

APPLIOATION FILED JUNE 16, 1905. RENEWED AUG. 21, 1906.

In ventor Jon N FER'REOL. MomwT byldl 13%,fi7m

AttyS.

JOHN FERREOL MONNOT, OF NEW YORK, N. Y,

PROCESS OF MAKING COMPOUND METALBODIES,

Specification of Letters Patent.

Patented April 30, 1907.

Application filed June 16, 1906. Renewed August 21, 1906. Swill No- 381.522.

- To all whom it may concern.-

Be it known that 1, JOHN FERREOL MON- NOT, a citizen of the United States, and a resident of the borough of Manhattan, city,

county, and State of New York, haveinvented certain new and useful Improvements in Processes of Making Compound Metal Bodies,

of. which the following is a specification, accompanied by drawings.

My invention relates to improvements in processes of making compound metal bodies, such articles comprising ingots, plates, sheets, rods, tubes, wire, structural shapes and other articles composed of layers or strata of unlike metals firmly and autogenously welded together.

My novel invention consists in the novel process herein described for producing such articles; all as more fully hereinafter set forth, matters of novelty being particularly pointed out in the appended claims.

Compound articles composed of unlike metals welded together may be used to great advantage in a variety of arts and for many different purposes, as combining the specific advantages of the component metals. "For example, plates, sheets, etc., composed of a strong but readily oxidizable metal such as iron or steel, covered with an impervious coherent coating of copper or other less oxidizable metal, may be used to great advantage in lieu of ordinary iron or steel plates, sheets,

etc., wherever such articles are to be exposed to the weather, air or other oxidizing influences, or to the action of corroding l quids,

- gases or vapors which readily attack iron or steel but do not attack at all, or at least to so serious an extent, the coating metal emloyed. Such articles composed of copper, grass, silver, aluminium, etc., backed with iron or steel may be used with great advantage where considerable strength or stiffness of metal is desired, coupled with the chemical, physical, electrical or other properties or color orappearance of thenon-ferrous metals mentioned. For electrical conductors it is desirable to combine the high electrical conductivity of copper, aluminium, etc., with the great strength of steel. Many other such uses might be pointed out. In all such cases, it is a prime requisite that the unlike metals shall be so inseparably united that a com ound ingot formed by joining them shall e ca able of great extension or working, as by rolling, drawing, etc. to make thin sheets, rods, angles, tubes, wire, etc.,

without separation of the united la ers, without development of seams, pores, aws,

etc. audit is in practice desirable that during such working, the strata of the joined metals shall maintain substantially their original relative proportions, even down tothe thinnest extended article produced.

The 'object of my present invention is to devise a method of making such compound ingots from such pairs of unlike metals as .steel and copper, steel and brass or other copper alloys, steel and silver, steel and aluminium, nickel and copper, or indeed any other pair of substantially unlike metals that is, metals oralloys of unlike. chemical nature; toform such bimetallic ingots of any desired shape or dimensions and with any desired relative proportions of the component metals; to produce such a strong, autogenous and weld-like union between such unlike metals as shall be incapable of se aration byheat or mechanical stress and sha 1 be adapted to permit indefinite'coextension ofthe joined metals in a: compound ingot by any of the ordinary methods of working with said union extending throughout and persisting at. all meeting points of the joined metals, and with the same relative proportions of the component unlike metals in the extended ware as in the original compound ingot to produce in such coextended ware articles which shall be comparable in price with ordinary coated metals, like electroplated, tinned and galvanized ware-while far superior in quality; to produce in such coated ware, coatings which shall be hard, dense, free from all pores, scale spots,'flaws, blisters or points of separation and shall be weldunited with the base metal throughout; and it is, further, my object in said method to accomplish these desirable ends by a simple, cheap and easy process requiring no highly skilled labor.

Suitable apparatus for carrying out my process is shown in the accompanying drawings in which Figure 1 shows a vertical section of suitable apparatus, showing the parts in one poinvention consists in thoroughly 0 eaning a r:

base or core of the more infusible metal bringing it up to a welding temperature without permitting access of air and, consequent IlO oxidation during heating; contacting with it' to cool under or during compression; and extending the compound ingot so formed to produce the extended ware desired. It is obvious that many ways of performing this broad process may be devised, and I shall hereinafter describe one such which may be used. For the sake of simplicity, I shall in the main describe the production of a compound steel-copper in ct, it being understood that this 1s typica Within the limits of my broad invention, of the manner of making compound ingots ofthe other pairs of unlike metals.

The steel core or base used may be an ingot, bar, bloom, billet or other commercial orm, and may be of any desired cross-section, as round, square, oval, etc., and of any size. It is to be cleaned in any of the ordinary well-understood ways, care onl being taken during the cleansing to insure t e complete removal of scale, oxid, dirt or other foreign matter which might later interfere With the absolute contact of the metal with the unlike metal. A clean metallic surface should be obtained.

Heating may be done in any desired way, provided that care be taken to prevent oxidation or other contamination of the cleaned metal. It is highly desirable that air should not gain access to the clean surfaces while they are hot. The heatin may be a done by the heat of the bath of t e molten unlike metal used for coating, or separately performed. I ordinarily prefer the latter as avoiding delay in the coating operation pro er Where a rapid succession of bases are to e coated, lar e baths of highly heated coating metal suc as copper, being difficult to handle, expensive an subject to rapid oxidation,'which renders it undesirable to prolong the period of immersion or contact. of the base to be coated. I therefore fre quently employ a sefparate preliminary heating bath of molten uxes or indifferent salts in which or by which the steel core may be heated to the necessary degree without opportunity for contamination or oxidationv of the clean metallicsurfaces. For this bath any fusible salt or flux not attacking the metal may be used, such as borax, sodium chlorid, sodium carbonate, fluor-spar, etc. and the core maybe heated therein until it reaches the proper temperature for contact i with the subsequent bath of highly heatng It should be heated to or ed molten copper. near-the weldin temperature, and, in cases where the ingot 1sto be directly worked after coating, sufficiently long to allow permeation is secure of heat throughout. In removing the heated core from the bath of molten flux, a coatin of the latter will be found to adhere and shiel the metal from access of air while in transit to the bath of molten copper. In contacting with the latter, the flux will flow away or slag off, before the copper as the latter, so to s eak, wets the steel, thereby insuring t at absolute metallic surfaces of the two metals shall contact without opportunit for access of air. For this flux bath in we ding copper to-steel, I may use fluor-spa'r. "This su stance melts at about 950 degrees centigrade, or somewhat below the melting point of copper, 1050 degrees, and a steel core immersed in or contacted with a bath of molten fiuor-spar readily attains the necessary de ree and amount of heat. With coating meta s of lower melting point than copper, such as aluminium, it may be'preferable touse another, flux. But of course Where in practice it may be deemed desirable, the reliminary flux bath may be omitted and the clean core lunged directly into or contacted with the ing is adopted, the steel core isheated to a temperature, or a temperature at weldin which it exhibits a measure of molecular activity, and upon the subsequent contact with the hi hly heated molten copper, a superficial alloy coating or film is formed, upon which the main mass of copper readily welds. Referring to the drawings, A represents a large crucible of any suitable character WhlCll may be filled-with a mass or bath, B, of hi hly heated molten copper or suitable meta? to be used for coating the compound ingot to be formed. Core or base, C, is of an unlike, more infusible metal, in this in stance assumed to be steel, and may be an ingot, billet, slab or bar of round, square, ovalor" other shape. Means are shown for handling this core or base, in this instance the means being a rod D which may he terms porarily connected to the core and is suitabl suspended, as by means ofth hook E, which may. be raised or lowered, by any suitable means, hereshown as a compressed air lift,

F. A guide G slides over the rod D and is iston; of the main cy inder carries a crossead on which are mounted the auxiliary .cylinders which actuate the guide G, carrying the casing I which may therefore be raised and lowered out of or into'the bath B of molten metal. In this instance a suitable chuck, J, is shown carried by the guide G for sup orting casing I. As shown, there d to the lower end of the billet or relative diameters of the core (1 and casing I are such that the interval between their sides, as indicated in Fig. 2, corresponds to the thickness of coating metal to be placed on core-C. T

In using the described 'ap aratus to carry out my process, a suitablyc eaned core, previously heated if desired, may be secured to the handling rod D, and the bottom plate or flange, K, secured toits' base. The core is then lowered into the bath-B, of molten copper orother suitable metal, preferably completely submerging it. Thiscoating metal is maintained in a molten, hi hly heated conditionbyany suitable heating means, as a furnace (not shown). When the core has reached substantially the temperature of the molten metal, which takes but a few minutes, the mold or casing I is lowered around core C until its lower ed e, O, enters the roove L of the bottom p ate or flange, K.

ore and casing are kept spaced apart to the proper distance by the guide G and by the cooperating groove and edgein bottom plate and easing, respectively. This distance is such as to form or segregate a layer ofthe molten metal of the thickness of the coating desired to appear on the resultant compound ingot. Segregation is done by thelowering of the casing As soon ascasing I and bot-. tom late K- come together, the casing is quick y lifted out of the molten metal bath by means of the air lift, carrying with it the contained core and the se regated layer of molten metal surrounding it, and is allowed to cool sufficiently to set saidlayer of coating metal firmly on the core. The whole 0 eration is preferably conducted as quicky as possible. The compound ingot so formed may then be removed from the casing or mo (1, and, in cases where the initial heat applied has been sufiicient to permeate the entire core, will be found still hot enough to permit direct rolling or other working. This immediate rolling, etc., has the double advantage ofsaving a reheating and'of perfecting the weld of the two metals, suppress ing small flaws or porosity which may exist or be formed in the coating metal.

In setting, the coating layer will cool more rapidly than the core metal, and as the coefiicient of expansion and contraction is gendure just describe erallygreater in coating metals like copper,

silver, etc., than in those used for cores, such as steel, in such an annular coatedingot' as is made by the ap aratus and in the proced the natural contraction of the coatingmetal .will produce enou h compression 'to complete the weld upon t e meeting surfaces of the two unlike metals.

In fact the pressure so obtained is oftenso "great as to produce damaging strains, cracks,

annular coating, extraneous pressure is usually necessary, for the reasons s ecified, although by contacting the perfect yclean base with molten unlike metal of a suitably high temperature I produce a superficial alloycoating or film of the two metals on which the coating will weld without pressure. .The a paratus shown and the procedure describe are to be understood as re resenting merely convenient and practica means for carrying out-my process. The procedure may be varied within the limits of mybroad disclosure and many specific forms of apparatus may be devised suitable for mypurpose. The particular type of a paratus used is not material to the successfu carrying out of my process.

What I claim and desire to secure byLetters Patent of the United States is 1. The process of producing compound metal ,bodies of unlike metals autogenously welded together which consists in contacting with a base of one such metal a hi hly heated molten mass of another and uh ike metal, segregating from such molten mass the layer thereof of molten metal in immediate proximity to and in contact with said base. and

allowing it to set thereagainst.

2. The process of producing compound metal bodies com risin steel and an unlike metal autogenous y we ded together which consists in contacting with a steel base a highly heated molten mass of an unlike metal, segregating from such molten mass the layer of molten metal in immediate proximity to and in contact with said steel base,

and allowing it to set thereagainst.

3. The process of producing compound metal bodies comprising steel and copper.

autogenously welded together which consists in contacting with a steel base a highly heated molten mass of copper, segregating from such molten mass of copper the layer of molten metal in immediate proximity to, and in contact with said steel base and allowing it to 'set there ainst.

4. e process of producing coextended compound metal ware composed of unlike metals autogenously welded together which consists in contacting with a base of one such metal a highly heated moltenmass' of another and un ike metal, segregating from such molteh mass the layer of molten inetal'in' I metal bodies of unlike metals fautogenously welded"together, which,-consists in immersing a base ofone such meta inahighly heated molten bath of another'and unlike metal, segregating from said bath the layer of said molten metal surrounding'sai'd base and allowing it to set thereagainst, I

6. he process of. producing compound metal bodies com risin steel and an unlike metal autogenous y we ded together, which consists in immersing a base of steel in a highlvheated molten'bath of such unlike metal, segregating from said bath the layer of said molten metal surrounding the base, and allowing itto set thereagainst.

7. The process of producing compound metal bodies comprising steel and copper autogenously welded together which consists 1n immersing a base .of steel in a highly heated molten bath of cop er, segregating from said bath the layer of molten copper surrounding the base, and allowing it.to set thereagainst.

8. The process of producing compound metal bodies of unlike metals autogenously welded together which consists in immersing a hot clean base of one such metal in a highly heated molten mass of another and unlike metal, segregating the layer of said molten metal in contact with said base, withdrawing base and contacting layer and allowing said layer to set against said base.

9. The process of producing compound -metal bodies com risin steel and an unlike metaligiiiutogenous y we ded together which 00 "hits in immersing a hot clean steel base hi hly heated molten mass of another dimike metal, segregating the layer of saidmolten metal in contact with said base,

withdrawing base and contacting layer, and allowing said layer to set against said base.

10. The process of producingcompound metal bodies comprising steeland copper autogenously welded to ether which consists 1n immersing a hot 0 can steel base in a highly heated molten mass of copper, segregating the layer of said molten copper in contact with said base, withdrawing base and contacting layer, and allowing-said layer to set against said base. a

11. Theprocess of producing coextended compound metal ware composed of unlike metals autogenously welded together which consists in immersinga hot clean base of one such metal in a hi hly heated molten bath of another and unli e metal, segregating the layer of said molten metal in contact with said base, withdrawing base and contacting layer, allowing the layer to set against the 'ferent' kind from the core, thereby complet- 'co0led bi-metallic ingot in a rolling mill or base, and coeir tendmg' the-compound ingot formedwhile still hot; 7 I a V 12. The process substantially as hereinafter described of making .bi-inetallic products,

molten metal for the coating of a different kind from the core, to produce a superficial allo of the core metal and coating metal out of t e action of the air, thereby insuring a perfect weld, segregating a layer of molten metal from said bath invcontact with said core, removing the core and its coating from the bath, and then-Working the sufficiently cooled bi-metallic ingot in a rolling mill or other suitable mill to produce bi-metallic plates, sheets, tubes, wires and like roducts.

13. The process substantially as ereinafter described of making bi-metallic products, such as ingots, sheets, tubes, wires and the like, of different metals welded to ether which consists in first cleaning the su ace'of a core of the desired metal, heating said core 0 preliminarily to a suitable temperature in such manner as to prevent oxidation, immersing the core in a bath of molten metal for the coating of a different kind from thecore thereby completing the heating of the 5 core and bringing 1t to awelding temperature, separating a layer of the molten metal from the bath of the desired thickness for the coating, removing the core and its coating from the bath and working the bi-metallic ingot in a rolling mill or other suitable mill to produce bi-metallic plates, sheets, tubes, wires and like products,

14. The process substantially as hereinafter described, of making com ound metal products of different metals we ded to ether which consists in immersin acore of t e desired metal in a bath of mo ten metal for the coating of a different kind from the core, thereby heating the core toaweldingtem perature, separating a layer of the molten metal from the bath of the desired thickness 'for the coating, removing the core and its coating from the bath, and permitting the coatin to solidify upon said core.

15. he process substantially as hereinaiter described of making bi-metallic products, such as ingots, sheets, tubes, wires and the like, of different metals welded together which consists in heating a core of the desired metal to a temperature near the melting point of the coating metal in such manner as to prevent oxidation, immersing the core in a bath of molten metal for the coating of a dif- I 2 5 ing the heating of the core and bringing it to a welding tern erature, segregating a layer of molten metal om said bath in contact with said core and then working the sufficiently I sheets, tubes, wires, and

other suitable mill, to roduce bi-metallic ike products.

1 6. The process substantially as hereinafter described of making compound metal prod ucts of different metals welded together which consists in surroundin a coreof the desired metal with a bath 0 molten metal for the coating of a different kind from the core thereby heating the core to a welding temperature, separating a layer of the molten metal around the core from the remainder of the bath of the desired thickness for the coatmg, removing the core and its coating from the bath and rmitting the coating to solidify upon saidiore.

17. The process substantially as hereinafter described of making bi-metallic products, such as ingots, sheets, tubes, wires and the like of different metals welded together which consists in heating the core to a high temperature in a bath of molten metal for the coating of a different kind from the core, to produce, a superficial alloy of the core metal and coating metal, thereby insuring a perfect weld, then separating a layer of the molten metal from the bath of the desired thickness for the coating and removing the core and its coating from the bath.

18. The process substantially as hereinafter described of making bi-metallic products, such as ingots, sheets, tubes, wires and the like of different metals welded together which consists in heating the core to a high temperature in a bath of molten metal for the coating of a different kind from the core, to produce a superficial alloy of the core metal and coating metal, thereby insuring a perfect weld, then separating a layer of the molten metal from the bath of the desired thickness for the coating and removing the core and its coating from the bath, then forcing the core and the coating metal together by pressure applied to the entire surface of contact of the metals while at a suitable temperature to perfeet the weld and sup ress any flaws in the coating metal, and fina tallic ingot' in a rolling mill or other suitable mill to produce bi-metallic plates, sheets, tubes, wires, and like roducts.

19. The process substantially as hereinafter described of making bi-met-allic products, such as ingots, sheets, tubes, wires and the like, of different metals welded together which consists in first heating the core in a bath of a molten metal, having a lower melting point than the coating metal, then im- J mersing the core thus heated in a bath of molten coating metal of a different kind from the core to finish heating the core and bring it to welding temperature, se arating a layer of the molten metal around tile core from the remainder of the bath of the desired thickness for the coating, and finally removing the core and its coating from the bath.

In testimony whereof I have signed this specification in the presence of two subscribing witnesses.

JOHN FERREOL MONN OT.

Witnesses:

A. L. OBRIEN, E. P. LA SAY.

ly working the bi-me- 

